Professional Documents
Culture Documents
PACKAGE
LOOP PIPELINE
STAGE
A1
08/01/15
Issued for
IDC
LHD
VXH
TK
Rev
Date
Description
Prepared
Checked
PM
PETROVIETNAM ENGINEERING
J.S.C
PVE
Document No:
304121-PVE-FD-PL-SPC-001
Number of pages: 54
(Including this cover)
TABLE OF CONTENTS
1.
INTRODUCTION ............................................................................... 5
1.1.
1.2.
1.3.
1.5.
Order of Precedence.............................................................................. 10
2.
3.
4.
5.
5.1.
5.2.
Welding ................................................................................................ 16
CHEMICAL PROPERTIES................................................................. 18
7.
7.1.
7.2.
7.3.
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7.5.
7.6.
Micrography.......................................................................................... 23
8.
DIMENSIONAL REQUIREMENTS..................................................... 23
8.1.
Diameter .............................................................................................. 23
8.3.
Length ................................................................................................. 24
8.4.
Straightness ......................................................................................... 24
8.5.
8.6.
8.7.
Jointers ................................................................................................ 25
8.8.
8.9.
9.
HYDROSTATIC TESTING................................................................. 25
10.
INSPECTION................................................................................... 25
10.1.
General ................................................................................................ 25
10.2.
11.
NON-DESTRUCTIVE TESTING......................................................... 27
11.1.
Procedures ........................................................................................... 27
11.2.
Personnel ............................................................................................. 28
11.3.
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11.4.
Examination of Pipe............................................................................... 28
REPAIRS ......................................................................................... 30
12.1.
12.2.
13.
14.
15.
16.
17.
APPENDICES .................................................................................. 35
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1.
INTRODUCTION
1.1.
Project Overview
The region currently receives natural gas from Block PM3 in Commercial
Arrangement Area (CAA) in the overlapping Vietnamese and Malaysia area of
the Gulf of Thailand, which feed the gas fired power plants and the fertilizer
plant at Ca Mau province in Vietnam. Nature gas is transported by PM3-CM
pipeline system, which was designed to transport a maximum of 2 billion
standard cubic meters natural gas per year. In future, additional gas
production from Block B&52 is planned.
Ca Mau Gas Processing Plant Project (PROJECT) was approved by Vietnam
Oil & Gas Group (Petrovietnam) in 2011 to recover LPG and condensate from
existing Block PM3 gas production and future Block B&52 gas production.
Feed gas from Block B&52 has been delaying, so PROJECT was adjusted
basing on Block PM3 as only feed gas source for process train-1. However,
PROJECT shall be designed to cover or/and meet the requirement of upgrade
when adding Block B&52 gas source (additional flow rate approximate 16.28
MMSCMD).
GPP will extract NGL from only Block PM3 gas production and produce: LPG,
condensate and residue gas. The liquid product (LPG and condensate) will be
stored in spheres/tanks at Terminal next to GPP and will be exported by truck
and barge via a new jetty at the existing port of Ca Mau 1 Power Plant. The
residue gas shall be sent back to the existing Gas Distribution Station (GDS)
and subsequently delivery to the existing consumers including the power and
fertilizer plants.
Gas consumption for future GPP and the booster compressor system (belong
to PROJECT) at Mui Tram Land Fall Station (LFS) is approximately 1 MMSCMD
by feed gas heating value (including fuel gas). Hence, to ensure gas supply
to power and fertilizer plants, the needing new loop pipeline for PM3-CM to
upgrade capacity of the existing pipeline. In order to safely and stably
operate the system, it's needed to have an additional compressor package
installed in LFS simultaneously with installing loop pipeline.
PROJECT shall include some packages:
- Package-1 Gas processing plant, terminal and export facilities, consist of
following:
+ Process units at GPP;
+ Terminal: to storage the liquid products (LPG and condensate);
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1.2.
1.3.
1.3.1. Definition
CLIENT
REPRESENTATIVE of CLIENT
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PVE/CONTRACTOR
PROJECT
INSPECTOR
MANUFACTURER
WORKS
ITT Documents
MR Documents
Within the context of this specification, the following words shall have the
meanings stated below:
agreement
may
shall
should
Indicates
that
recommended
among
as
several
particularly
possibilities,
suitable,
one
is
without,
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ASME
ASTM
ASNT
BOF
CEPcm
CTOD
CVN10
DWTT
FL
Fusion Line
GMAW
HAZ
HV10
ID
Inner Diameter
ISO
Joule
LSAW
MPa
Mega Pascal
MPI
MPS
MPQ
NACE
NDT
OD
Outer Diameter
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1.4.
PCN
SAW
SMYS
UOE
UT
Ultrasonic Testing
UTS
API RP 5L1
Recommended
Practice
for
Railroad
API RP 5LW
API RP 1110
Gas
Transmissions
and
Distribution
Piping
System
ASME Section V
Non-Destructive Examination
ASME Section II
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ASTM E112
Standard
Test
Methods
for
Determining
ASTM E709
British Standards, BS
BS EN 2910
Methods
for
Radiographic
Examination
of
BS EN 10204: 2004
Petroleum
and
Materials
for
Natural
use
Gas
in
Industries
H2S-containing
Order of Precedence
Since this document refers to many codes and standards and also to other
specifications, in case of any conflict, CLIENT should be notified by the
MANUFACTURER for clarification. Unless otherwise agreed, the following
order of precedence is expected to be followed:
1. Vietnam Government Regulations;
2. Vietnam Country Standards;
3. CLIENT supplied technical documents;
Rev.: A1
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4. Project Specifications;
5. International Codes and Standards.
2.
3.
GENERAL REQUIREMENTS
The design data that is to be used in this pipeline is contained in Datasheet
No.: 304121-PVE-FD-PL-DAS-001 Data Sheet for Line Pipe.
Pipe manufacturing shall be in accordance with this Specification and API 5L:
2012, 45th Edition. The pipeline is designed according to DNV-OS-F101;
pipeline welding during installation will be in accordance with Doc. No.:
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MANUFACTURER OBLIGATIONS
The MANUFACTURER shall furnish all the required materials, supervision,
labour, equipment, testing and inspection services, and expenses incidental
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5.1.
General Requirements
Please delete
Appendix 4.
Girth weld shall
be performed by
Pipeline
installation
contractor. Pipe
manufacturer
have not enough
equipment and
skill for
performing Girth
weld (that weld5.2.
connect 2 pipes
together)
The pipe material shall conform to the grade API 5L: 2012, 45th Edition
L450M or X65M, product specification level 2 (PSL 2) as specified in the
Purchase Order.
The MANUFACTURERs Manufacturing Procedure Specification (MPS) shall be
subject to qualification as described in Appendix 1 of this Specification.
Weldability tests shall be conducted in accordance with Appendix 3 and
Appendix 4 of this Specification.
Inspection and test requirements are summarized in Appendix 3.
Manufacturing Procedure
All manufacturing, examination, inspection, testing and repair shall be
performed in accordance with the procedures. The procedures shall cover all
manufacturing steps from the steel making to finished pipe and the system
for quality control in each step. The control of received materials shall also be
included in the manufacturing procedures.
The manufacturing procedure shall be submitted to CLIENT for approval. No
manufacturing shall commence until CLIENT approval is received.
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b.
c.
Any change in pipe forming, alignment, clamping and joint design for
welding;
d.
e.
Any change in the number of passes and number of welding wires used
in each pass;
f.
g.
h.
Any change in the method of cold expansion and any increase in the cold
expansion above that used during qualification.
Rev.: A1
Page 15/35
Please delete
Appendix 4.
Girth weld shall
be performed by
Pipeline
installation
contractor. Pipe
manufacturer
have not enough
equipment and
skill for
performing Girth
weld (that weld
be connected 2
pipes together)
5.3.
After execution of the longitudinal seam, the run-on and run-off tabs shall be
removed by flame cutting or sawing only (mechanical breaking of tabs shall
be for bidden).
The pipes shall be cold expanded or hydrostatically expanded to provide
permanent strain in the range at 0.8% to 1.5%. Pipe shall be sized,
straightened and hydrostatically tested.
The MANUFACTURER shall conduct all examinations, inspection, dimensional
checks and mechanical tests described in this Specification and API 5L: 2012,
45th Edition. The results of all the examinations, dimensional checks and
mechanical tests shall conform to the requirements of this Specification and
API 5L: 2012, 45th Edition. All results shall be recorded and provided to
CLIENT in accordance with the requirements of this Specification and API 5L:
2012, 45h Edition. Weldability tests (as per Appendix 4) shall be carried out
for offshore sections using pipes with the highest CEPcm.
Welding
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The weld deposits obtained from the consumables shall satisfy the
fracture toughness and hardness requirements of this Specification and
shall have tensile properties that are equal to or slightly higher than those
of the base metal. Weld metal shall not overmatch the maximum Ultimate
Tensile Strength of the base metal by more than 20%.
All welding consumables shall conform to ASME Boiler and Pressure Vessel
Code, Section II Part C or approved equivalent.
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Charpy tests in accordance with Section 7.3, but with the sets removed
from the following locations:
-
CHEMICAL PROPERTIES
The chemical composition of the steel shall be as given in Table 6-1. The
tolerances and acceptable range applied for each element shall be provided
in the MPS. The percentage present of every element in Table 6-1 shall be
stated in the product analysis report of the finished pipe even if some
elements are not added on purpose but are present as residuals only. No
element shall be added to the steel without the written approval of CLIENT.
Ladle and product analyses shall be furnished to CLIENT concurrently with
production for each heat of steel. For continuous cast processes, the term
"heat" shall define each casting.
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According to API 5L
2012, Annex J,
Table J.1
(Plate manufacturer
can not produce the
steel plate if the
chemical
composition is more
strictly than API 5L
standard
requirement
Symbol
Carbon
0.12
Silicon
Si
0.45
Manganese
Mn
1.65
Sulphur
0.01
Phosphorus
0.02
Copper
Cu
0.35
Nickel
Ni
0.3
0.5
Molybdenum
Mo
0.1
0.5
Chromium
Cr
0.3
0.5
Niobium
Nb
0.05
Vanadium
0.05
0.1
Titanium
Ti
0.05
0.06
Aluminium (total)
AI
0.05
0.06
Nitrogen
0.008
0.012
Boron
0.0005
Calcium
Ca
0.005
0.5
0.08
Notes:
1. The sum of Nb+V+ Ti shall not exceed 0.15 percent.
2. The soluble Al: N ratio shall not be less than 2:1. Altotal 0.06%, N 0.012%.
3. Mo 0.1%; B 0.0005%; Cu 0.35%; Ni 0.3%; Cr 0.3%.
4. The carbon equivalent value (CEPcm) based on product analysis shall be calculated by the
following formulae, shall not exceed 0.22% for the line pipe material and weld.
Doc. No.: 304121-PVE-FD-PL-SPC-001
Rev.: A1
Page 19/35
CE Pcm =C+
V
10
Mo
15
Cr+Mn+Cu
20
Si
30
Ni
+5B
60
7.
MECHANICAL TESTING
7.1.
Test Frequency
The mechanical testing for qualification and production shall be done
according to Appendix 3, Testing and Inspection.
In addition, 1 pipe /
1 heat or 2 pipes /
heats of each OD
and wall thickness
combination.
According to DNV
OS F101, Section
7, A803 and other
project
requirement
7.2.
In addition three of the completely finished pipes of the first day production
shall be selected at random for testing to verify that the submitted
manufacturing procedure results in fully acceptable pipes. These pipes shall
be subjected to the inspection and tests as described in Appendix 1, for
Qualification of Pipe Manufacturing Procedure.
Tensile Test
Acceptance criteria for tensile tests should be per Table J.2, API 5L: 2012,
45th Edition.
Tensile testing will take sample as the mentioned in Appendix 2, Hardness
Survey. The tensile, yield and elongation properties of base metal shall be
determined.
The actual yield strength of the pipe material shall not exceed the specified
minimum yield strength as required by API 5L: 2012, 45th Edition, grade
specified by more than 120 MPa (17,404 psi) i.e, Minimum SMYS: 450 MPa,
Maximum SMYS: 570 MPA. The actual Ultimate Tensile Strength (UTS) shall
be maintained within the range of 535 MPa to 760 MPa. When the round bar
specimen is used, the yield strength measured shall be the 0.2% proof
stress.
The minimum required elongation shall be determined in accordance with the
Table J.2 (note f) in API 5L: 2012, 45th Edition.
Tensile properties shall be determined from specimens removed from the
pipe in its final condition (i.e. after mechanical expansion).
Rev.: A1
Page 20/35
Modify:
Transverse of
pipe body
(T180)
According to API
5L, Table 20,
Table J.7, Annex
7.3.
J and Appendix
2
of this spec. 7.3.1.
Tensile strength of weld seam shall be as per Table J2 API 5L: 2012, 45th
Edition.
The ratio of yield strength to tensile strength in base material shall not
exceed 0.93 in the transverse and longitudinal directions.
Toughness Test
General
The fracture toughness of the pipe shall be determined in all cases by the use
of Charpy V-notch impact tests in accordance with Section 9.8, Annex J of
API 5L: 2012, 45th Edition.
Charpy test specimens shall be full-size (10mm x 10mm) transverse
specimens whenever possible.
Three sets shall be tested on each test ring taken for tensile testing with
three specimens taken from the each of the following positions:
Weld centerline
Note 1:
Heat Affected Zone location shall be the zone which gave the lowest energy values in Fusion
Line/ Fusion Line + 2mm/ Fusion Line + 5mm tests carried out for Manufacturing Procedure
Qualification.
Charpy test specimens shall be located at the mid-thickness of the pipe with
the axis of the notch perpendicular to the pipe surface. Specimen locations
for weldments are shown in Figure A of Appendix 1.
7.3.2. Test Temperature
The Charpy V-notch impact test temperature shall be as equal as minimum
design temperature for thicknesses equal to or below 20mm. For linepipe
thicknesses above 20mm, test temperature shall be 10oC below minimum
design temperature.
7.3.3. Charpy V-Notch Energy Requirements
In order to have adequate toughness against the ductile fracture, the Charpy
V-Notch energy and shear area requirements for line pipe material API 5L:
2012, 45th Edition, X65M shall be observed as per table below, which contains
the following nominal values for the minimum average/individual impact
values and minimum average/individual shear area.
Doc. No.: 304121-PVE-FD-PL-SPC-001
Rev.: A1
Page 21/35
Please delete.
according to
Table 20, Table
J.7 and Appendix
2 of this spec
Charpy V-Notch
Energy
Minimum Average
(J)
Minimum Individual
(J)
Transverse
45
38
Longitudinal
67.5
57
Wall Thickness
17.5 WT 20mm
20 < WT 25mm
90J (average)
95J (average)
28
7.4.
Production tests shall be at the rate of one pipe per heat. Three full thickness
transverse specimens shall be taken from one length of the pipe from each
Two
heat supplied.
According to API 5L,
DWTT production tests shall be conducted at 0C.
Section 9.9 and Table 20
Each specimen of a set of two production test specimens shall exhibit a
minimum of 85 percent shear area on the fracture surface.
Retest criteria shall be as per Section G.3, Annex G, API 5L: 2012, 45th
Edition.
7.5.
Marco/Hardness Tests
The weld shall be evaluated by removing a pipe cross section containing the
weld. The section shall include the weld fusion line, heat affected zone (HAZ)
and parent metal on both sides of the weld and shall be polished and etched
for examination. The weld shall have complete penetration and fusion. The
geometry, including plate edges and inside and outside weld profile shall be
Rev.: A1
Page 22/35
Please delete.
According to API
5L, Table J.6 and
Table 18
7.6.
Vickers hardness testing with a 10kg load shall be conducted on the weld
cross sections. The hardness traverse shall be in accordance with Appendix 2
of this specification. The hardness shall not exceed 270 HV10 on the base
material, weld metal and 300 HV10 in the heat affected zone (HAZ).
If any results exceed this hardness limit, two further sections from the same
weld shall be prepared and tested. If either of these specimens give results
that exceed the hardness limit the entire heat shall be rejected. CLIENT will
define additional tests (if required) for all other heats of steel being supplied.
Micrography
One specimen of 30mm long in the rolling direction shall be extracted from
base material, at 20mm from the weld toe and at 180 to the weld seam.
They shall be properly polished and etched. They shall be examined at 5mm
from the external and internal surfaces and at mid thickness, every 10mm in
the rolling direction, with a magnification of X100. The microstructure shall
not show banded structure in terms of segregated bands of carbides or
carbide components.
8.
DIMENSIONAL REQUIREMENTS
The requirement for mass tolerance will be referred to Section 9.14, API 5L:
2012, 45th Edition. The dimensions, length, weights, and straightness of pipe
shall comply with API 5L: 2012, 45th Edition and the following:
8.1.
Diameter
8.1.1. Body
Dimensional tolerances on outside diameter (OD) of the pipe body shall not
exceed 0.5%; +0.5% of the specified nominal outside diameter (O.D),
measured with a diameter tape.
The out-of-roundness of the outside diameter of the pipe at any point along
its length shall not exceed the following:
(Max.O.D - Min.O.D)
Nominal .O.D
1.0 percent
Peaking of the pipe body at the weld shall not deviate more than 1.5mm from
the design form.
Rev.: A1
Page 23/35
8.1.2. Ends
The tolerance on the nominal internal diameter within 100mm of the pipe
ends shall be within tolerance 1.6mm.
Nominal ID = Nominal OD - 2 x Nominal Wall Thickness
Please modify: "a
tape"
same with other
project
The out-of-roundness at the pipe ends shall not exceed the following:
(Max.I.D - Min.I.D)
Nominal .I.D 0.75 percent
Wall Thickness
The wall thickness of each pipe shall be checked during production to ensure
uniformity.
Please delete.
because the
thickness of the bend
shall be reduced
more than 3 mm
(based on actual
thickness) at the
extrados point after
hot induction bending.
8.3.
The bend
manufacturer and
other project only
control the min
thickness
Please modify:
11.5m and
8.4.
12.2m.
Because some
pipe must be
to cut 400 450mm for
production
tests
8.5.
The pipe wall thickness at any point shall not deviate by more than 1 mm
(10 mm < wall thickness 20 mm) and +1.5 mm/ -1 mm (wall thickness >
20 mm) from the specified nominal wall thickness.
Note that for any pipe designated to be used for factory induction bends, the
pipe wall thickness tolerance shall be + 1.5mm/ 0.0mm from the specified
nominal wall thickness).
Length
The pipe shall be supplied to the following length requirements unless
otherwise specified in the Purchase Order:
The nominal pipe length shall be 12.2m;
Rev.: A1
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8.6.
8.7.
8.8.
8.9.
The max radial
offset shall
comply with
Table 14 of API
5L, Section 9.13
9.
bead
INSPECTION
10.1. General
The MANUFACTURER shall bear full responsibility for the conformity of the
supplied items to all requirements of this Specification. The MANUFACTURER
shall for this purpose, take all necessary measures, making use of suitable
means, devices and qualified personnel to ensure permanent and effective
control at each stage of manufacture.
All inspection operations carried out by the MANUFACTURER during pipe
manufacture shall be regularly reported and updated. These reports shall be
available for inspection by the INSPECTOR at any time.
If during pipe production, unacceptable defects are found at a rate of 5% or
more for a specific type of defect, the INSPECTOR shall have the right to
Doc. No.: 304121-PVE-FD-PL-SPC-001
Rev.: A1
Page 25/35
Rev.: A1
Page 26/35
The MANUFACTURER shall take all reasonable precautions to ensure that the
pipe surface is free from imperfections that might interfere with the efficient
application of an external coating. In addition, the metal surfaces shall be
sufficiently clean and smooth to permit Non-Destructive examination. All
loose scale shall be removed, and pitting and rough surfaces removed by
grinding. Pipe shall have a workmanlike finish, and the MANUFACTURER shall
remove those by grinding, mechanical marks and abrasions, such as cable
marks, scores, etc., and also imperfections such as scabs, seams, laps, tears,
and slivers, even though these imperfections may be shallow enough to be
within wall thickness tolerances.
The maximum height of outside and inside weld bead shall be not more than
3.0 mm. All pipes shall be checked for weld bead height and shall be
measured and recorded three times per shift.
Please delete
Acceptance
criteria shall be in
accordance with
API 5L, Annex J,
Section 9.10.2
11.
NON-DESTRUCTIVE TESTING
The types and extent of NDT required for LSAW line pipe shall be per API 5L:
2012, 45th Edition.
11.1. Procedures
All NDT shall be performed in accordance with written procedures. These
procedures shall be approved by CLIENT or its authorized representative,
prior to the testing.
Doc. No.: 304121-PVE-FD-PL-SPC-001
Rev.: A1
Page 27/35
Rev.: A1
Page 28/35
Rev.: A1
Page 29/35
REPAIRS
Rev.: A1
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Please modify:
"one pipe
end..."
Rev.: A1
Page 31/35
Pipe steel grade (steel name) (see Table 1, API 5L: 2012, 45th Edition);
Except as allowed by 11.2.3 and 11.2.4, API 5L: 2012, 45th Edition, the
required markings shall be applied durably, legibly and be as follows:
On the outside surface of the pipe, in the sequence listed in see 11.2.1,
API 5L: 2012, 45th Edition, starting at a point between, 450 mm and 760
mm from one of the pipe ends;
On the inside surface of the pipe, starting at a point at least 150 mm from
one of the pipe ends.
If agreed, low-stress die-stamping or vibro-etching on the pipe surface may
be used, subject to the following limitations:
Such marks shall be on the pipe bevel face or within 150 mm of one of the
pipe ends;
Such marks shall be at least 25 mm from any weld;
Doc. No.: 304121-PVE-FD-PL-SPC-001
Rev.: A1
Page 32/35
Cold die-stamping [at temperatures < 100 C (210 F)] of plate, strip or
pipe not subsequently heat treated shall be done only if rounded or blunt
dies are used.
For pipe intended for subsequent coating, if agreed, marking may be done at
the coater's facility rather than at the pipe mill. In such cases, traceability
shall be ensured, e.g. by application of a unique number (by individual pipe
or heat of steel).
If a temporary protective coating (see section 12.1.2, API 5L: 2012, 45th
Edition) is applied, the markings shall be legible after such coating.
In addition to the markings specified in section 11.2.1, API 5L: 2012, 45th
Edition, the pipe length shall be marked as follows, in metres to two decimal
places (feet to tenths of a foot) or, if agreed, in a different format and shall
be as follows:
The individual pipe length (as measured on the finished pipe) shall be
marked:
At a convenient location on the outside surface of the pipe;
If agreed, at a convenient location on the inside surface of the pipe.
For pipe furnished with couplings, the length as measured to the outer
face of the coupling shall be marked.
If agreed, the manufacturer shall apply a daub of paint, approximately 50
mm in diameter, on the inside surface of each length of pipe. The paint
colour shall be as per Table 27, API 5L: 2012, 45th Edition if the pipe grade is
applicable; for all other grades, the paint colour shall be as specified in the
purchase order.
14.
15.
Rev.: A1
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truck or vessel. However, approval of these documents shall not relieve the
MANUFACTURER of its responsibility for damage during shipment.
All dimensional tolerances and pipe surface conditions specified herein and in
API 5L: 2012, 45th Edition shall apply to the pipe as received by CLIENT or its
authorised representative, at the shipping destination.
16.
Please delete.
Because
weldability test
apply to girth
weld, Pv Pipe
dont perform
Girth welding at
Pv Pipe factory
Rev.: A1
Page 34/35
APPENDICES
Appendix 1: Qualification of Pipe Manufacturing Procedure
Appendix 2: Hardness Survey
Appendix 3: Testing and Inspection
Appendix 4: Girth Welding Tests
Girth welding
dont carry out at
PV Pipe
Rev.: A1
Page 35/35
APPENDIX 1
QUALIFICATION OF PIPE MANUFACTURING PROCEDURE
(06 pages)
shall be subjected to the inspection and tests as described below in order to qualify the
manufacturing procedure. These pipes may be selected by the INSPECTOR.
If any of the first day production tests fail, production shall be halted and all pipes
produced shall be identified and rejected. The reason for the failure shall be identified
to the satisfaction of CLIENT or its authorised representative. The manufacturing
procedure shall be amended. A new set of tests shall be conducted on the first days
production to the new procedure. MPQT shall be performed for each OD and wall
thickness combination.
A1
The selected pipe shall be inspected for compliance with dimensional tolerances, wall
thickness and surface condition in accordance with the requirements of this
Specification.
A2
Non-Destructive Tests
The entire pipe shall be subject to ultrasonic examination and either electro-magnetic or
magnetic particle examination for longitudinal and transverse defects and laminations.
This shall include MPI examination of pipe ends.
The weld seam shall be subject to x-radiography along its full length.
A3
Chemical Analysis
A chemical analysis shall be carried out on the pipe body and on an all-weld-metal
coupon. Please adding: "Chemical analysis on an all-weld metal are for information only"
According to API 5L
A full chemical analysis shall be made on inside weld bead and outside weld bead. As a
minimum, all the elements as per the composition requirement of the applicable
consumable specification shall be analysed.
A4
Mechanical Tests
Tensile Tests
Two tensile specimens (one longitudinal and one transverse directions to pipe axis) in
accordance with API 5L: 2012, 45th Edition shall be removed from each pipe end.
Strip specimens shall be used unless otherwise agreed by CLIENT or its authorised
representative.
The yield strength, tensile strength, elongation and yield to tensile strength ratio shall
conform to the requirements of this Specification.
An all-weld-tensile test specimen shall be prepared. The yield strength shall lie in the
range specified for the yield strength of the pipe.
Please modify: "The result of Tensile strength on the all-weld metal
Please delete.
shall be as per Table J.2 API 5L: 2012, 45th edition"
Weld metal is Charpy V Tests
area to be
Charpy V specimens shall be removed from two (2) locations (1 location at each end of
mixed
between Base the pipe).
one (1)
metal and
welding wire, The specimens shall be cut transverse to the pipe axis. Sets of 3 Charpy specimens
welding flux.
Yield strength shall be notched at each location, in the weld metal, FL, FL + 2mm and FL + 5mm
can not lie in locations as shown in Figure A of Appendix 1. Among the three positions FL, FL + 2mm
the range
and FL + 5mm, the one giving the lowest average value shall be selected for routine
specified for
the yield
production test and shall be referred to as "Heat Affected Zone Charpy test. The shear
strength of the
area shall also be reported and shall meet requirements as specified in Section 7.3.
pipe.
Charpy V tests shall also be conducted in the base metal, weld metal and HAZ to
determine full Charpy energy and shear transition curves to ASTM A370. The tests shall
be carried out in the transverse direction for a minimum of 6 temperatures ranging
from -70 to 0C. Results and curves shall be supplied for information only.
3. For fusion line specimens the specimen centreline intersects the fusion line at
specimen mid-thickness
4. FL+ 2 and FL+ 5 specimen locations are shown exaggerated for clarity
Specimens for procedures and trial production shall be etched to aid notch location
Crack Tip Opening Displacement Test (CTOD)
3 sets of CTOD tests shall be carried out in accordance with BS 7448, on full pipe
thickness, transverse test pieces. The notch positions shall be in the weld centreline and
HAZ locations at a test temperature of 0C. The measured fracture toughness of base
metal and the weld metal shall, as a minimum, have a CTOD value of 0.15 mm.
Guided Bend Test
Appendix 1: Qualification of Pipe Manufacturing Procedure
2 bend test weld specimens shall be cut and tested according to API 5L: 2012, 45th
Edition; 2 sides bend tests.
Drop Weight Tear Test
average
Drop Weight Tear Tests shall be carried out in accordance with API 5L: 2012, 45th
Edition and API RP 5L3. Tests shall be performed on the pipe at 0C. The minimum
individual shear area shall be 85%.
In addition a full transition curve shall be established on one pipe from each grade. The
Please modify:
"Hardness
shall not
exceed 300
HV10 for HAZ
and 270 HV10
for Base metal
and Weld
metal"
The two (2) macro sections shall be cut, one from each end of the pipe. They shall be
examined to determine the acceptability of the weld in accordance with the
Manufacturing Procedure Specification. At each of these locations a Vickers Hardness
survey shall be carried out in accordance with Appendix 2. Hardness shall not exceed
250 HV10 for the weld cap and the parent material, weld root and weld mid thickness.
Base metal metallurgical microstructure and grain size evaluation shall be carried out at
Please delete. mid-thickness. Photographs of microstructure shall be supplied. Acceptance criteria shall
According to be as outlined in Section 7.6.
API 5L, Table
Please delete. Because Girth welding test shall not be
J.6 and Table A6
Girth Welding Tests
perform at PV Pipe factory
18
A full girth weld shall be produced using the test pipe and tests conducted in
accordance with Appendix 4.
A7
Records
The MANUFACTURER shall submit to CLIENT or its authorised representative, the pipe
manufacturing procedure qualification test reports giving the results of all tests required
by this Specification for review and approval.
A8
Rejection
In case of results that are not satisfactory with respect to this Specification, the pipe
tested as well as the preceding pipes shall be rejected. The causes of failure shall be
investigated and reported to the INSPECTOR. The burden of proof that the rejected
Appendix 1: Qualification of Pipe Manufacturing Procedure
pipes meet the requirements lies solely with the MANUFACTURER. Production shall
resume only after the procedure has been suitably revised to the satisfaction of CLIENT
or its authorised representative. A new qualification test pipe shall be produced
according to this Specification.
A9
Hydrostatic test
APPENDIX 2
HARDNESS SURVEY
(03 pages)
Figure b1: Sample and Test Piece Orientations and Locations SAWL Pipes
Notes:
1. W transverse sample, centred on the weld
2. T180 transverse sample, centred 180 from the longitudinal weld
3. T90 transverse sample, centred 90 from the longitudinal weld
4. L90 longitudinal sample, centred 90 from the longitudinal weld
Table b.1 - Number, Orientation and Location of Test Pieces per Sample for
Mechanical Tests
Number, orientation and
location of test pieces per
Type of
Sample
pipe
location
Type of test
samplea
Specified outside diameter D
mm (in)
SAWL
Tensile
1T180c,d
CVN
3T90
Pipe body
Tensile
1We
CVN
Guided-bend
2We
Hardness
1We
Seam weld
Notes:
a) For double-seam pipe, both longitudinal weld seams in the pipe selected to represent the test
b) If agreed, annular test pieces may be used for the determination of transverse yield strength by
the hydraulic ring expansion test in accordance with ASTM A 370.
c) For deep-water pipelay, additional longitudinal tests might be specified, with the requirements
and test frequency being as agreed.
d) For double-seam pipe, both longitudinal weld seams in the pipe selected to represent the test
unit shall be tested.
APPENDIX 3
TESTING AND INSPECTION
(05 pages)
During production
Test/Inspection
Frequency
Remarks
Frequency
Remarks
VISUAL/DIMENSIONAL
INSPECTION
Dimensions
All pipes
All pipes
Straightness
All pipes
Surface defects
All pipes
Out-of-roundness
All pipes
All pipes
3 pipes per shift,
min.
3 pipes per shift,
min.
External &
internal
All pipes
External &
internal
All pipes
Recorded 3
All pipes
All pipes
ULTRASONIC
EXAMINATION
Plates
All plates
All plates
Longitudinal weld
All pipes
All pipes
Weld repairs
MPI
Longitudinal weld
All pipes
Manual
examination
Qualification Tests
During production
Test/Inspection
Frequency
Remarks
Frequency
Remarks
Bevel + 150 mm
Pipe ends
All pipes
internal and
external weld
Bevel + 150
mm internal
All pipes
and external
surfaces
allAllground
areas that suspect
ground areas
have defects
weld surfaces
procedure
tests
RADIOGRAPHY
longitudinal weld
All pipes
procedure
tests
RESIDUAL MAGNETISM
All pipes
100 % weld
200mm each
All pipes
ends
MECHANICAL TESTS
Tensile tests
3 pipes
2 pipes
1 pipe per 50
2 pipes
3 pipes
1 pipe per 50
pipes
23pipes
1 pipe per 50
Charpy V-Notch
CharpyV
Notch
transition
1 per pipe
curve
size
N/A
Minimum 2 per
heat
Minimum 2 per
heat
Minimum 2 per
heat
Qualification Tests
During production
Test/Inspection
Frequency
Remarks
Frequency
Remarks
minimum
design
temperature(1)
Metallographic
Examination(1)
Bend Test
CTOD Test
Fracture Arrest
HYDROTEST
1 pipe
N/A
1 pipe
1 pipe
1 pipe
1 pipe
2 side bend
1 per pipe
1 pipe per 50
Minimum 2 per
heat
Minimum 2 per
heat
Minimum 2 per
heat
N/A
size
2 3pipes
pipes
1 pipe per 50
All pipes
All pipes
1 per heat
1 per heat
Minimum 2 per
heat
CHEMICAL
COMPOSITION
Heat analysis
Product analysis
WELDABILITY
2 per heat
1 girth seam
test
5L 2012.
QUALIFICATION TEST
Minimum 2 per
1 pipe per 50
heat on pipe
body
N/A
Qualification Tests
During production
Test/Inspection
Frequency
Remarks
Frequency
WELDING
CONSUMABLES
Manufacturers
Test
Each batch
Each batch
Certificates
REPAIR
WELD
PROCEDURE
1 per pipe
size
shallow repair
QUALIFICATION TEST
Note:
1. These items will be selected within the 3 available pipes for these tests.
2 (two)
Remarks
APPENDIX 4
GIRTH WELDING TESTS
(04 pages)
SUPPORTING DATA
Supporting data demonstrating the suitability of the linepipe for field welding or similar
past report shall be supplied at the qualification stage. The data shall demonstrate
that the pipe can be welded by either shielded metal arc welding (SMAW) or
mechanised/semi-automatic welding, typically by the gas metal arc welding (GMAW)
process, without preheat, post-heat, post-weld heat treatment. The data shall
demonstrate that the pipe meets the requirements of this Appendix after welding.
Where such data does not exist, or is deemed unsatisfactory by CLIENT, the tests
specified in this Appendix shall be carried out. The necessity for such tests will be
determined at the qualification stage.
D2
GENERAL
Maximum hardness 250 HV10 on the weld root and the weld cap.
Separate tests are required for each material grade/ heat number.
The requirements for testing are stated below. The MANUFACTURER may submit
alternative proposals for review and approval by CLIENT.
D3
MATERIAL
The base material shall be chosen to reflect the maximum carbon equivalent of the
pipes in question. However, the steel used may have the product maximum carbon
equivalent (CE in Section 6 of this Specification) minus 0.02% or Pcm minus 0.001%.
CLIENT or its authorised representation, shall approve the heat analysis of the steel or
pipe to be used for the weldability tests.
D4
TEST WELDS
A test weld shall be prepared and shall consist of butt welding together two (2) pipe
sections as noted below, unless otherwise agreed by CLIENT or its authorised
representative. The weld shall comprise of two sections of 5m minimum length,
making a total minimum welded pipe length of 10m, which shall be subject to the
tests detailed below.
The weld shall be made with the shielded metal arc welding process, using low
hydrogen electrodes capable of meeting the Charpy acceptance criteria of this
Specification.
Welding position 5G, vertical down for 28 linepipe
Heat input 1kJ/mm 0.1 kJ/mm
Preheat and post-heat shall not be carried out.
PWHT shall not be carried out.
D6
General
All the tests shall be carried out in accordance with this specification.
Dimensional tolerance
Dimensional checks shall be carried out at the fit-up stage to provide a record of pipe
dimensions prior to welding and to confirm pipe is within the required tolerances.
Radiographic Examination
Appendix 4: Girth Welding Tests
Before cutting the specimens, the test weld shall be 100% radio graphed in
accordance with this Specification.
Hardness Survey
Vickers hardness survey shall be conducted on the above macro sections, according to
Figure B1, Appendix 2.
Charpy V Test
Charpy tests shall be taken in weld and HAZ (FL, FL+2mm and FL+5mm), in
accordance with this Specification, with specimens taken from the 3 or 9 oclock
position at mid-thickness. Acceptance criteria for impact values and test temperature
shall be as per this Specification only.
Macrography and Micrography
3 specimens shall be taken, one at 12 oclock and one at 6 oclock position from weld
seam and subject to macrography and micrography examination.
Additional Tests
The test weld shall be subject to the following additional tests:
D7
Ultrasonic examination
All test welds as described above shall meet the following requirements.
Maximum hardness shall be 250HV10 at the weld root and the weld cap.
Tensile properties and Charpy V notch energy in accordance with the requirements of
this Specification.
The MANUFACTURER should note that the girth weld tests shall be acceptance tests
for the pipes, and they form part of the Manufacturing Procedure Qualification Test.
D8
REPORTING
Following completion of the test programmed, the results and final report from the
MANUFACTURER shall be submitted directly to CLIENT or its nominated specialist. The
final report shall include, as a minimum, the following:
Weld Procedure Specification;
Weld Procedure Qualification record giving details of the actual welding parameters for
each pass, consumables used, bevel geometry;
Mill Certificates for materials used;
Dimensional records;
NDT and mechanical test results; (including any failures)
Any other testing agreed with CLIENT or its authorised representative;
Any necessary photographs, macrographs and micrographs (if any)
The interpretation of results and conclusions of the MANUFACTURER, including his
recommendations for production welding of pipe installation.